Hat block



J. AUER l-l AT'BLOCK Filed Aug. 1, 1959 June 2, 1942.

NVENTOR ATTORNEY Patented June 2, 1942 warren STATES egreuroreica HAT BLOCK John Auer, East Norwalk, Conn. Application August f1, 1939, Serial No. 287,688

8 Claims.

This invention relates to a support or block for blocking and pouncing hats, and has for an object to provide a block which will absorb moisture during the blocking operation without swelling or expanding and thus will retain its size and shape.

In blocking hats it is desirable that the hat be fully dried out while on the block so that it will not change its shape or size after being removed from the block, and from the standpoint of production it is desirable that the hat be quickly dried while ironing it so as to speed up the operation.

It is therefore another object of the invention to provide a block for supporting the hat during the ironing or blocking operation which will absorb the moisture and quickly and thoroughly dry the hat.

With the foregoing and other objects in View I have produced a construction as illustrated in the accompanying drawing forming a part of this specification. It is, however, to be understood that various changes and modifications may be employed within the scope of the invention.

In this drawing:

Fig. 1 is a transverse section through a hat block constructed according to this invention;

Fig. 2 is a detailed section substantially on line 22 of Fig. 1;

Fig. 3 is a section through a portion of the block showing a further application;

Fig 4 is a section through a portion of a rim block employing the principles of the invention which may be used for ironing the brim of a :2.

proper size and shape. It can be thoroughly and completely dried while on the block. The block will retain its size and shape during the blocking operation, and the hat being completely dried.

Will not shrink or change its shape after being removed from the block.

I accomplish these desirable results by means of a block having a surface portion supporting the hat composed of a moisture absorbent clay, preferably a fine baked clay of proper shape and smooth surface. A clay which is suitable for making bricks, after it has been properly sifted to remove coarse particles, has been found satisfactory. This clay when shaped and baked with an unglazed surface gives a support for the hat which is sufficiently porous to absorb moisture from the hat during the ironing or blocking operation, and it will absorb this moisture without expanding or changing its size or shape.

The clay support may be provided in various ways, the block construction shown in the drawing being very satisfactory. This comprises a base or closure 5 of metal or other suitable material offset'at its central portion providing an annular shoulder 6 leaving outer flange portions 1. The body of the block comprises a supporting member 8 preferably of sheet metal of proper gauge such as stainless steel as this resists deterioration and has a low coefficient of expansion. It is preferably, for example, of about one sixteenth inch thick having throughout its surface small perforations 9. The outer surface is covered with a layer of clay I!) of suitable thickness, preferably about a quarter of an inch thick but I am not limited to this as the thickness may be varied considerably, and made considerably thicker, and it is also preferred to cover the inner surface with a similar layer H, although this is not absolutely necessary. The clay is baked on the support 8 with an unglazed surface, or it may be slightly glazed to give it a smooth hard surface but not enough to prevent ready absorption of moisture. The surface can be made smooth and uniform. This gives a layer of material which is porous and highly moisture absorbent.

At the lower edge of the support 8 is a flange member 12 which is secured to the member 8 by any suitable means such as welding i3, and it has an upwardly extending flange Hi at the .4 inner edge of the horizontally extending flange portion E5, the flange l4 being spaced from the member 8 about the thickness of the inner layer or lining H to embrace the lower free edge thereof and prevent it chipping oif. Similarly the outwardly extending flange portion !6 is offset at i! spaced from the member 8 substantially the thickness of the layer H] to protect the free edge of this layer. When mounted on the base 5 the flange member I2 seats on the flange portion 1 of the base and with the flange it embracing and closely fitting the shoulder 6.

It is preferred to provide means for holding the body portion'of the block on the base For this purpose a wire loop i8 is welded to the top of the member 8, and a rod I9 having a hook 20 may be hooked over this loop and passing down through the base may be secured in a collar 2! by any suitable means such as a set screw 22 accessible for operation through an opening 23 in the supporting tubular member 24. The member 2| is secured to the base by any suitable means such as welding 25. The tubular supporting member 24 may also be welded to the base as indicated at 25 and has at its lower end a flange member 21 by which it may be secured to a support 28, such as a table of a machine or a bench, and the flange may be secured to this support by any suitable means such as a screw 29. Additional steadying supports may also be provided for the base 5 such as downwardly extending legs welded to the base 5 at 3! and resting on the support 28.

Means is provided for producing heat within the block. For this purpose I have shown an electric resistance heater coil 32 mounted in a,

suitable insulated support 33 on the base 5 and connected at its opposite ends with the blade contacts 3 3 of a suitable attachment plug 35 whereby it may be connected to a suitable source of electric current the usual manner. Also, to assist in the rapid drying of the hat and maintainin the clay in a dry absorbent condition a suction may be provided on the inside of the block. For this purpose a pipe 236 communicates with the interior of the block and may be connected to any suitable source of suction.

In blocking, the hat indicated at 3'3, is placed on the block and then ironed until dry by a suitable ironing means indicated diagrammatically at 38, the whole or any desired portion of the hat being ironed as is the usual practice. As is the usual practice the felt in the hat is moistened by a wet cloth or sponge and then ironed with a hot iron. The vapor generated by the hot iron is quickly absorbed by the baked clay, which has a great capacity for absorbing this moisture, and the clay remains substantially dry and highly moisture absorbent during continuous operation. The absorbing and drying qualities are also increased by the heating means 32 and the reduced pressure or suction provided on the interior of the block which draws air and moisture through the hat and the block, thus drying the hat and the clay portions of the block. The suction also helps to maintain the hat in position on the block.

Instead of having the hat directly on the baked clay material this material may be first covered with a cloth 39 as shown in Fig. 3, if preferred, and the hat 3'! placed on this covering.

The same principle may be used for ironing the brim of the hat. Thus a base member 45 as shown in Fig. 4 of general angular shape in cross section and of general annular or oval shape to correspond with the shape of the hat may have secured to the lower wall thereof a strengthening member 4| of sheet metal, such as stainless steel, or other suitable material corresponding to the member 8 of Fig. 1 and having throughout its surface numerous small perforations 32. It may be covered with the layers of clay 43 and 4 corresponding to the layers H] and H of the first form and baked on the support the same as previously described. This support 4| may be secured to the base Ml by any suitable means such as welding 45, and the layer 43 is shaped to fit the shape or curvature of the brim 45 of the hatS'I. The member 4! is substantially hollow providing a space i! at the inner side thereof with the base 43 in which may ber 53.

be placed the electric heating element 58 corresponding to the element 32 in the first form. Suction may also be provided in this space and therefore on the hat blocking member by means of a suction pipe 49 connected to the space 41 and any suitable suction device, not shown. It will of course be understood that in ironing the brim 46 the moisture is absorbed by the baked clay 43 and id quickly drying the brim the same as the body of the hat in the first form, and the drying operation is speeded up and increased by the heater 18 and the suction in the chamber ll. Of course if desired a covering of cloth may be placed on the outer surface of the layer 43 to prevent direct contact of the hat with the clay, the same as shown in connection with Fig. 3.

In the modification shown in Fig. 5 the block is made pricinpally of a solid block 58 of the baked clay molded and formed to the desired shape. It is preferably recessed in its lower side or face as indicated at El leaving a substantially annular rim portion 52 about the lower edge of the body. The lower edge of this rim portion is protected by the member 53 preferably of metal, similar to member !5 of the first form. This member 53 is of substantially channel form having inner and outer flanges 54 and 55 against the surfaces of the clay body, or that is, the rim portion 52 is between these flanges so that it is protected by the member 55 against nicking or breaking. The member 53 may have secured to it a series of anchor members 55 welded to the member at 5? and having heads 58 embedded in the clay so that when it is hardened they are securely anchored in the clay and the member 53 properly attached thereto. For mounting the block on an ironing machine or other device or support, a pipe 59 may be molded in the clay and anchored therein by any suitable means, such as splitting and spreading the upper end as shown at $9. This pipe is also preferably perforated as shown at 5| so suction on the pipe will draw moisture through the clay to facilitate drying. This block is used substantially the same as the present solid wooden block and is designed to take its place. The member 53 may be omitted so the rim is plain, and increased strength secured by using a heavier glazed coating on the surfaces corresponding to those covered by mem- The projecting end of the pipe is substantially on the face (lower side) of the block and may be provided with the usual means for mounting it on a support, such as slots 62, or a securing flange, or other means. Such a block canbe used for all finishing work as well as ironing.

It will be evident from. the above that the baked clay material will absorb moisture from the ironing operation without expanding or swelling. Thus the hat is ironed or blocked accurately to shape and it will be thoroughly and quickly dried, increasing production and preventing shrinking or changing the shape of the hat after removal of the hat from the block, as would occur if the hat was removed before being thoroughly dried and the pores of the felt are still open. Various types of clay may be used, but a clay similar to'that used for making brick with the coarse materialtaken out has been found very satisfactory. The supporting members 8 and 4| may be of various materials of the proper strength and stiffness, but they are preferably of stainless steel with small perforations throughout its surface as this material is resistant to rust or deterioration by the moisture and has a very small coefiicient of expansion so that it maintains its shape. This greatly strengthens the clay material which is preferably baked on it in layers of about a quarter of an inch thick so that it is porous and highly moisture absorbent, but if theextra strength is not required the block may be shaped of this baked clay material alone. In the operation of blockingthe hat is ironed until completely dry. If taken off before becoming completely dry or when still damp and warm the pores of the felt are still open so that when it dries after being removed from the block it has a tendency to shrink. This clay block permits complete drying on the block, which is difficult in old types of blocks. This block does not expand or contract and therefore it always keeps its exact shape I and measurements. Although the drawing shows the block of the shape of a finished hat it can of course be of any shape desired, such as cone or other shape, and can be used for pouncing a hat on a cone as it has a smooth surface. The suction not only assists in drying the hat but also keeping the block dry and it also helps to hold the hat in position on the block. The result of using this material is to provide a block comprising porous highly moisture absorbent material. It is preferably a baked clay, and this can be surface smoothed sufficient- 1y to iron a hat on it directly, although, as indicated, a cloth covering or cap could be placed on the clay between it and the hat if desired. 7

Having thus set forth the nature of my invention, what I claim is:

1. A hat block comprising a hollow, perforated sheet metal member, a layer of moisture absorb ent baked clay covering the surface ofsaid member and forming a support for the hat to be blocked, and means for producing a suction within the hollow member.

2. A hat block comprising a hollow, thin, perforated member, a layer of moisture absorbent baked clay covering the inner and outer surfaces of said member forming a support for the hat to be blocked, and means for producing a suction within said member.

3. A hat block comprising a base member having an annular shoulder, a body comprising a perforated sheet metal member having inwardly and outwardly extending flanges at its edge seated on said base and embracing said shoulder, a layer of baked clay covering the inner and outer surfaces of said perforated member with their lower edges supported by said flanges, and means for securing said member to the base.

4. A hat block comprising a base member having an annular shoulder, a body comprising a thin, hollow, perforated member seated on said base and embracing said shoulder, a layer of porous, moisture absorbent clay covering the outer surface of said perforatedmember and forming a support for the hat to be blocked, and means for producing a suction within the hollow member.

5. A hat block comprising .a perforated metal support, and porous moisture absorbent baked clay covering the outer surface of said support and forming a support for the hat being blocked, the hat engaging surface of the clay being sufficiently glazed to give it a smooth hard surface but insuflicient to prevent ready absorption of moisture.

6. A hat block comprising a body of moisture absorbent baked clay having its hat engaging surface sufliciently glazed to give a smooth hard surface forming a support for the hat being blocked, and said surface being sufiiciently porous to absorb and conduct moisture from the surface to the baked clay behind said surface so it is not retained on said surface.

7. A hat block comprising a hollow, thin, perforated member, moisture absorbent baked clay covering the surface of said member and having a smooth hard surface forming a support for the hat to be blocked, and means for producing a suction within the hollow member.

8. A hat block comprising a body having a layer of moisture absorbent baked clay with its hat engaging surface sufficiently glazedto give a smooth surface to support a hat, said surface being sufficiently porous toabsorb and conduct moisture to the baked clay behind said surface so it is not retained on said surface, and a heating means on the opposite side of said layer from the hat for drying the clay.

. 1 JOHN AUER. 

